Catalysts, activating agents, support media, and related methodologies useful for making catalyst systems especially when the catalyst is deposited onto the support media using physical vapor deposition

Abstract

Use of physical vapor deposition methodologies to deposit nanoscale gold on activating support media makes the use of catalytically active gold dramatically easier and opens the door to significant improvements associated with developing, making, and using gold-based, catalytic systems. The present invention, therefore, relates to novel features, ingredients, and formulations of gold-based, heterogeneous catalyst systems generally comprising nanoscale gold deposited onto a nanoporous support.

What is claimed is: 
     
       1. A method of oxidizing a compound, comprising the steps of:
 providing a nanoporous support medium,
 wherein the nanoporous support medium comprises a plurality of composite particles, each composite particle comprising a plurality of guest particles incorporated onto a host particle wherein the ratio of the average particle size of the host particles to the guest particles is in the range of 10,000:1 to 10:1, 
 wherein the nanoporous support medium comprises activated carbon and further comprises titania, 
 and wherein the nanoporous support medium comprises physically vapor deposited elemental gold clusters of dimensions of about 0.5 nm to about 50 nm on the nanoporous support medium; and, 
 
 causing the nanoporous support medium catalyst system to catalytically contact the compound. 
 
     
     
       2. The method of  claim 1  wherein the oxidizing of the compound occurs in a respiratory protection system. 
     
     
       3. The method of  claim 1  wherein the oxidizing of the compound occurs in a personal respiratory protection system. 
     
     
       4. The method of  claim 3 , wherein the personal respiratory protection system is selected from the group consisting of a mask and an escape hood. 
     
     
       5. The method of  claim 1  wherein the compound is CO. 
     
     
       6. The method of  claim 1  wherein the compound is an organic compound. 
     
     
       7. The method of  claim 6  wherein the organic compound comprises at least one oxygen atom. 
     
     
       8. The method of  claim 6  wherein the organic compound comprises at least one double bond. 
     
     
       9. The method of  claim 6  wherein the organic compound comprises one oxygen atom and one double bond. 
     
     
       10. The method of  claim 6  wherein the organic compound comprises a hydrocarbon. 
     
     
       11. The method of  claim 10  wherein the hydrocarbon further comprises at least one heteroatom chosen from the group consisting of N, O, P, S or halogens. 
     
     
       12. The method of  claim 1 , wherein the nanoporous support medium comprises at least one water soluble metal salt. 
     
     
       13. The method of  claim 12 , wherein the at least one water soluble metal salt is selected from the group consisting of an alkali metal, an alkaline earth metal, and mixtures thereof. 
     
     
       14. The method of  claim 12 , wherein the at least one water soluble metal salt comprises a potassium salt. 
     
     
       15. The method of  claim 14 , wherein the at least one water soluble metal salt comprises potassium carbonate. 
     
     
       16. The method of  claim 12 , wherein the activated carbon comprises potassium carbonate. 
     
     
       17. The method of  claim 16 , wherein the activated carbon is derived from coconut shells that naturally contain potassium carbonate. 
     
     
       18. The method of  claim 1  wherein the activated carbon comprises nanoporosity. 
     
     
       19. The method of  claim 1 , wherein the nanoporous support medium further comprises alumina. 
     
     
       20. The method of  claim 1 , wherein the weight loading of physically vapor deposited gold is in the range of 0.005 to 2 wt. % based upon the total weight of the nanoporous support medium and the physically vapor deposited gold. 
     
     
       21. The method of  claim 1  wherein at least the guest particles comprise nanoporosity. 
     
     
       22. The method of  claim 1  wherein the guest particles comprise a particle size of less than about 10 μm. 
     
     
       23. The method of  claim 1  wherein the guest particles comprise nanoparticles. 
     
     
       24. The method of  claim 1  wherein the host particles comprise a mesh size of greater than about 30. 
     
     
       25. The method of  claim 1  wherein the nanoporous support medium comprises activated carbon coated with nanoparticles.